1999-2000 Buell Lighting X1 Service Manual - PDF DOWNLOAD

1999-2000 Buell Lighting X1 Service Manual - PDF DOWNLOAD

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1999-2000 Buell Lighting X1 Service Manual - PDF DOWNLOAD

Language :English
Pages :538
Downloadable : Yes
File Type : PDF

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1999-2000 Buell Lighting X1 Service Manual - PDF DOWNLOAD

FOREWORD
GENERAL

This Service Manual has been prepared with two purposes mind. First, it will acquaint the user with the construction the Buell product and assist in the performance of bas maintenance and repair. Secondly, it will introduce to the p fessional Buell Technician the latest field-tested and facto approved major repair methods. We sincerely believe that t Service Manual will make your association with Buell pro ucts more pleasant and profitable.

HOW TO USE
YOUR SERVICE MANUAL
Information is arranged as follows:
Section 1-Maintenance
Section 2-Chassis
• Section 3-Engine
Section 4-Fuel System
Section 5-Electric Starter
Section 6-Drive/Transmission
Section 7-Electrical
Appendix A-Tools
Appendix B-Electrical Connectors
Appendix C-Metric Conversions
Appendix D-Hose and Wire Routings

TABLE OF CONTENTS:

1999-2000 Buell Lighting X1 Service Manual - PDF DOWNLOAD

SECTION 1-MAINTENANCE
1 1 General 1-1
Servicing a New Motorcycle
Safe Operating Maintenance
Shop Practices
Repair Notes
Safety
Removing Parts 1-1
Clean Ing 1-1
Disassembly and Assembly 1-2
Checking Torques on Fasteners with Lock Patches1-2
Repair and Replacement Procedures 1-2
Hardware and Threaded Parts 1-2
Wiring, Hoses and Lines
Instruments and Gauges
Bearings
Bushings
Gaskets
Lip Type Seals
O-Alngs (Preformed Packings)
Gears
Shafts
Part Replacement
Cleaning
Part Protection
Cleaning Process 1-3
Rust or Corrosion Removal 1-3
Bearings 1-3
Inspecting 1-3
Leak Dye 1-3
T col Safety 1-3
Air Tools 1-3
Wrenches 1-3
Pliers/Cutters/Prybars 1-3
Hammers 1-3
Punches/Chisels 1-3
Screwdrivers 1-3
Ratchets and Handles 1-4
Sockets 1-4
Storage Units 1-4
1 2 Side Views 1-s
1 3 Fluid Requirements 1-6
General 1-6
United States System 1-6
Metric System 1-6
Steering Head Bearing Grease 1-6
Primary Oriverrransmission Fluid 1-6
Front Fork Oil 1-6
Brake Fluid (1999 Models) 1-6
Brake Fluid (2000 Models) 1-6
Page No
Fuel 1-6
Engine Oil 1-6
Recommended Oil Grades (table) 1-6
Regular Maintenance Intervals (table) 1-7
1 4 Battery (1999 Models) 1-11
General 1-11
Inspection 1-11
Storage 1-12
Removal 1-12
Installation 1-12
1 5 Battery (2000 Models) 1-14
General 1-14
Battery Testing 1-14
Voltmeter Test (Table) 1-14
Disconnection and Removal , 1-15
Cleaning and Inspection 1-15
Storage 1-15
Removal 1-15
Installation and Connection 1-16
1 6 Engine Lubrication System 1-11
Checking Engine Oil Level 1-17
Recommended Oil Grades (Table) 1-17
Changing Engine Oil and Filter , 1-18
1 7 Brakes (1999 Models) 1-19
General 1-19
Bleeding Brakes 1-19
Rear Brake Pedal 1-20
1 8 Brake Pads and Rotors (1999
Models) 1-21
Brake Pads 1-21
Brake Rotors 1 -21
Brake Rotor Drive Pins 1-21
Brake Rotor Thickness 1-21
Brake Carrier Lateral Free Play 1-22
Brake Carrier Rotational Free Play 1-22
1 9 Brakes (2000 Models) 1-23
General 1-23
Bleeding Brakes 1-23
Rear Brake Pedal 1-25
Iii
Page No
1 1 o Brake Pads and Rotors (2000
Models) 1-26
Brake Pads 1-26
Brake Rotors 1-26
Brake Rotor Thickness 1-26
1 11 Tires and Wheels 1-21
Tire Inflation 1-27
Tire Pressures (table) 1-27
Wheel Bearings 1-27
1 12 Clutch 1-28
Transmission Fluid 1-28
Adjustment 1-29
1 13 Rear Belt Deflection 1-30
Inspection 1-30
Adjustment 1-31
Axle Alignment 1-31
Deflection Adjustment 1-31
1 14 Rear Belt and Sprocket 1-32
General 1 -32
Cleaning 1 -32
Inspection 1-32
Rear Sprocket 1-32
Drive Belt 1-32
Drive Belt Wear Analysis (table) 1-33
1 15 Primary Chain 1-34
Inspection 1-34
Primary Chain Tension (table) 1-34
Adjustment 1-35
1 16 Preload Adjustment 1-36
General 1 -36
Adjustment 1-36
1 17 Suspension 1-38
Adjustment 1-38
Front Fork Rebound 1-38
Front Fork Compression 1-38
Rear Shock Rebound 1-38
Rear Shock Compression 1-38
iv
Page No
1 18 Front Fork Oil 1-39
Fork Oil Change 1-39
Fork Oil (table) 1-39
1 19 Steering Head Bearings 1-40
Inspection 1-40
Lubrication 1-40
Adjustment 1-41
1 20 Spark Plugs 1-42
Inspection 1-42
1 21 Air Cleaner Filter 1 43
Removal 1-43
Installation 1-43
1 22 Throttle Cables 1-44
Adjustment 1-44
Idle Adjustment 1-44
1 23 Ignition Timing 1-45
Inspection 1-45
Static Timing 1-45
~
1 24 Handlebars 1-47
Inspection 1-47
Adjustment 1-47
1 25 Headlamp 1-48
Inspection 1 -48
Adjustment 1-48
1 26 Storage 1-49
General 1-49
Removal from Storage 1-49
Page No
1 27 Troubleshooting 1-50
General 1-50
Engine 1-50
Starter Motor Does Not Operate 1-50
Engine Turns Over But Does Not Start 1-50
Starts Hard 1-50
Starts But Runs Irregularly or Misses 1-50
Spark Plug Fouls Repeatedly 1-51
Pre-Ignition or Detonation (Knocks or Pings} 1-51
Overheating 1 -51
Valve Train Noise 1-51
Excessive Vibration 1-51
Engine Lubrication System 1-51
Oil Does Not Return To Oil Tank 1-51
Engine Uses Too Much Oil/Smokes 1-51
Engine Leaks Oil From Cases Etc 1-51
Electrical System 1-51
Alternator Does Not Charge 1-51
Alternator Charge Rate Is Below Normal 1-51
Fuel 1-51
Fuel System Floods 1-51
Poor Fuel Economy 1-51
Transmission 1-51
Shifts Hard 1-51
Jumps Out of Gear 1-51
Clutch 1-52
Slips 1-52
Drags or Does Not Release 1-52
Chatters 1-52
Chassis 1-52
Irregular/Inadequate Brale Action 1 -52
Handling Irregularities 1-52
SECTION 2-CHASSIS
2 1 Specifications 2-1
Dimensions 2-1
Weight 2-1
Capacities 2-1
Tire and Position 2-1
Torque Values 2-1
2 2 Tire Specifications 2-4
General 2-4
Tire Fitment-Cast Wheels (table} 2-4
Tire Fitment-P/M Wheels (table) 2-4
2 3 Vehicle Identification
Number 2-5
General 2-5
~ 2 4 Wheels 2-6
General 2-6
Troubleshooting 2-6
Wheel Service (table) 2-6
Page No
2 5 Front Wheel (1999 Models) 2-8
Removal 2·8
Disassembly 2-8
Cleaning, Inspection and Repair 2-8
Assembly 2-9
Installation 2-1 o
2 6 Front Wheel (2000 Models) 2-11
Model Year Change 2-11
Removal 2-11
Disassembly 2-11
Cleaning and Inspection 2-11
Assembly 2-12
Installation 2-13
2 7 Rear Wheel 2-14
Removal 2-14
Disassembly 2-15
Cleaning, Inspection and Repair 2-15
Assembly 2-15
Installation 2-15
2 8 Checking Cast Rim Runout 2-11
General 2-17
Rim Lateral Runout 2-17
Rim Radial Runout 2-17
Whe!I Runout (table) 2-17
2 9 Tires 2-18
Model Year Change 2-18
General 2-18
Removal 2-18
Cleaning and Inspection 2-18
Installation 2-19
Checking Tire Lateral Runout 2-19
Checking Tire Radial Runout 2-19
Adjustment 2-20
Wheel Balancing 2-20
2 10 Brakes (1999 Models) 2-21
General 2-21
Brake Troubleshooting (table) 2-21
2 11 Front Brake Master Cylinder
(1999 Models) 2-22
Removal 2-22
Disassembly 2-2 2
Cleaning, Inspection and Repair 2-23
Assembly 2-23
Installation 2-24
2 12 Front Brake Caliper
(1999 Models) 2-25
Removal 2-25
Disassembly 2-25
Cleaning, Inspection and Repair 2-26
Assembly 2-26
Installation 2-27
2 13 Front Brake Line
(1999 Models) 2-29
Removal 2-29
Installation 2-29
2 14 Rear Brake Master Cylinder
(1999 Models) 2-31
Removal 2-31
Disassembly 2-31
Cleaning, Inspection and Repair 2-32
Assembly 2-32
Installation 2-32
2 15 Rear Brake Caliper
(1999 Models) 2-34
Removal 2-34
Disassembly 2-34
Cleaning, Inspection and Repair 2-34
Assembly 2-35
Installation 2-35
2 16 Rear Brake Line
and Switch (1999 Models) 2-37
Removal 2-37
Installation 2-38
2 17 Brakes (2000 Models) 2-40
General 2-40
Brake Troubleshooting (table) 2-41
2 18 Front Brake Master Cylinder
(2000 Models l:::: 2-42
Removal 2-42
Disassembly 2-42
Cleaning and Inspection 2-43
Assembly 2-43
Installation 2-44
2 19 Front Brake Caliper
(2000 Models) 2-45
Removal 2-45
l'Disassembly 2-45
Cleaning and Inspection 2-46
Assembly 2-46
Installation 2-46
vi
Page No
2 20 Front Brake Line
(2000 Models) 2-48
Removal 2-48
Installation : 2-48
2 21 Rear Brake Master Cylinder
(2000 Models) 2-50
Removal 2-50
Disassembly 2-50
Cleaning and Inspection 2-51
Assembly 2-51
Installation 2-51
2 22 Rear Brake Caliper
(2000 Models) 2-53
Removal 2-53
Disassembly 2-53
Cleaning and Inspection 2-53
Assembly 2-54
Installation 2-54
2 23 Rear Brake Line
and Switch (2000 Models) 2-56
Removal 2-56
Installation 2-57
2 24 Fron t Fork 2-60
General 2-60
Removal 2-60
Disassembly : 2-60
Cleaning, Inspection and Repair 2-62
Assembly 2-62
Installation 2-64
2 25 Fork Stem and
Bracket Assembly 2-65
Removal/Disassembly 2-65
Cleaning, Inspection and Repair 2-65
Assembly/Installation 2-65
2 26 Steering Head Lock ~ 2-67
Removal 2-67
Installation 2-67
2 27 Swingarm 2-69
Removal 2-69
Disassembly 2-70
Cleaning/Inspection 2-70
Assembly 2-71
Installation 2-71
\
Page No
2 28 Rear Shock Absorber 2-14
Removal 2-74
Installation 2-74
2 29 Suspension Theory 2-16
Definitions 2-76
Damping 2-76
Compression 2-76
Rebound 2-76
Vehicle Sag 2-76
Aider Sag 2-76
Preload 2-76
General 2-76
2 30 Suspension Adjustments 2-11
Spring Preload 2-77
Adjustments 2-77
Troubleshooting 2-77
General Suspension Problems (table) 2-77
Rear Suspension Problems (table) 2-78
Front Suspension Problems (table) 2-78
Aider Suspension Preferences (table) 2-79
2 31 Throttle Control 2-80
Model Year Change 2-80
Removal/Disassembly 2-80
Cleaning, Inspection and Repair 2-80
Assembly/Installation 2-80
2 32 Clutch Control 2-82
Adjustment 2-82
Removal/Disassembly 2-82
Clutch Cable-Lower 2-82
Clutch Hand Control 2-82 "
Assembly/Installation 2-83
Clutch Cable-Lower 2-83
Clutch Hand Control 2-83
2 33 Instrument Support 2-84
Removal ::-:-:- _ 2-84
Installation 2-84
2 34 Handlebars 2-85
Removal 2-85
Installation 2-85
2 35 Exhaust System 2-86
Removal/Disassembly 2-86
Muffler 2-86
Exhaust Header 2-86
Assembly/Installation 2-88
Muffler 2-88
Exhaust Header 2-89
Page No
2 36 Footrests (1999 Models) 2-90
Removal 2-90
Installation 2-90
2 37 Footrests (2000 Models) 2-91
Removal 2-91
Installation 2-91
2 38 Sprocket Cover 2-92
Removal/Disassembly 2-92
Assembly/Installation 2-92
2 39 Front Fender 2-93
Removal/Installation 2-93
2 40 Rear Fender 2-94
Removal 2-94
Installation 2-94
2 41 Belt Guards 2-95
Removal 2-95
Installation 2-95
2 42 Chin Fairing 2-96
Removal 2-96
Installation 2-96
2 43 Fuel Tank Cover 2-97
Model Year Change : 2-97
Removal 2-97
Installation 2-97
2 44 Air Scoop 2-98
Removal 2-98
Installation 2-98
2 45 Trunk 2-99
Removal 2-99
Installation 2-99
2 46 Tail Section 2-100
Removal 2-100
Cleaning 2-1 oo
Disassembly 2-1 oo
Assembly 2-102
Installation 2-102
2 47 Windscreen 2-103
Removal 2-103
2 48 Seat (1999 Models) 2-104
Removal 2 -104
Installation 2 -104
Attachment Points 2- 104
2 49 Seat (2000 Models) 2-105
Model Year Change 2-1 05
Removal 2-105
Installation 2- 105
Attachment Points 2-105
2 50 Side Stand 2-106
Model Year Change 2-106
General 2- 106
Removal/Disassembly 2- 106
Assembly/Installation 2-106
SECTION 3-ENGINE
3 1 S ·t· t· pecI Ica ions
General
Camshaft Specifications
Engine lgntion Specifications
Service Wear Limits
Torque Values
3 2 Engine
Model Year Change 3 -5
General 3 -5
Cylinder 3-5
Crankcase 3-5
Gearcase 3-5
Fuel 3-5
Gasoline/alcohol Blends 3-5
Lubrication 3-5
Adjustment/Testing 3-6
General 3-6
Compression Test Procedure
Compression Test Results Qable)
Cylinder Leakage Test /
Diagnosing Smoking Engine/
High Oil Consumption
Air Leakage Test (table)
3 3 Stripping Motorcycle
For Engine Repair
Disassembling Engine for Cylinder Head Repair
Engine Crankcase Replacement or
Complete Engine Removal
3 4 Installing The Engine
Engine Crankcase Installation 3- 10
Engine Installation After Cylinder Head Repair 3-11
viii
Page No
3 5 Cylinder Head 3 -12
Removal 3-12
Disassembly 3-14
Cleaning, Inspection and Repair 3-15
Rocker Arms and Bushings 3-16
Replacing Valve Guid es 3 - 17
Valve Stem Clearances (table) 3-17
Grinding Valve Faces and Seats 3-18
Neway Valve Seat Cutters (table) 3-18
Replacing Valve Seats 3-19
Lapping Valve Faces and Seats 3-19
Assembly 3-20
Installation 3-21
Push Rod Selection (table) 3-21
Lower Rocker Box Hardware (table) 3-22
3 6 Cylinder and Piston 3 23
Removal/Disassembly 3-23
Cleaning, Inspection and Repair 3-24
Checking Gasket Surface 3-24
Measuring Cylinder Bore 3-25
Cylinder Bore Service Wear Limits (table) 3-25
Measuring Piston 3-26
Fitting Cylinder to Piston 3-26
Boring and Honing Cylinder 3-26
Fitting Piston Rings 3-26
Final Cylinder Bore Sizes (table) 3-26
Connecting Rod Bushing 3-28
Assembly/Installation 3-29
3 7 Lubrication System 3 30
Checking and Adding Oil : 3-30
Changing Oil and Filter 3-30
Winter Lubrication 3-30
3 8 Oil Hose Routing 3 31
General 3-31
3 9 Oil Tank 3 32
Removal/Disassembly 3-32
Assembly/Installation 3-32
3 1 O 011 Pressure
Indicator Switch 3 33
General 3-33
Oil Pressure Signal Light 3-33
Oil Pressure 3-33
Troubleshooting Oil Pressure Signal Light (table) 3-33
3 11 Crankcase Breathing
System 3-34
General 3-34
Page No
3 12 Oiling System
(Color Foldout) 3-35
3 13 Oil Pump 3-36
General 3-36
Removal/Disassembly 3-37
Cleaning, Inspection and Repair 3-38
Assembly/Installation 3-38
3 14 Oil Filter Mount 3-39
General 3-39
Disassembly 3-39
Cleaning/Inspection 3-39
Assembly 3-39
3 15 Valve Tappets
(1999 Models} 3-40
General 3-40
Removal 3-40
Cleaning/Inspection 3-40
Installation 3-41
3 16 Hydraulic Lifters
(2000 Models} 3-42
General 3-42
Removal 3-42
Cleaning/Inspection 3-42
Installation 3-43
3 17 Gearcase Cover and
Cam Gears (1999 Models} 3-44
General 3-44
Removal/Disassembly 3-44
Cleaning, Inspection and Repair 3-45
Cam and Pinion Gear Identification, Inspection,
and Selection 3-45
Cam/Pinion Gear Coler Code & Diameter (table) 3-46
Bushing Inspection and Removal 3-47
Bushing Installation 3-47
Gear Shaft Specifications (table) 3-47
Bushing Reaming 3-48
Assembly/Installation 3-50
3 18 Gearcase Cover and
Cam Gears (2000 Models} 3-52
Model Year Change 3-52
General 3-52
Removal/Disassembly 3-53
Cleaning and Inspection 3-53
Page No
Cam and Pinion Gear Identification, Inspection,
and Selection 3-53
Cam/Pinion Gear Color Code & Diameter (table) 3-54
Bushing Inspection and Removal 3-55
Bushing Installation 3-55
Gear Shaft Specifications (table) 3-55
Bushing Reaming 3-56
Assembly/Installation 3-58
3 19 Crankcase (1999 Models} 3-60
General 3-60
Adjustment/Testing 3-60
Flywheel End Play 3-60
Flywheel End Play Spacers (table) 3-60
Disassembly 3-61
Crankcase Halves 3-61
Flywheels 3-63
Cleaning/Inspection 3-63
Replacing Flywheel Washers 3-65
Lapping Connecting Rod Races 3-65
Fitting Rod Bearings 3-66
Fitting Sprocket Bearings 3-67
Fitting Pinion Bearings 3-67
Race Diameter and Crank Pin Size (table) 3-67
Connecting Rod Specifications (table) 3-67
Pinion Shaft Bearing Selection (table) 3-70
Lapping Engine Main Bearing Races 3-71
Assembly 3-71
Flywheels 3-71
Crankcase Halves ~ 3-73
3 20 Crankcase (2000 Models} 3-77
Model Year Change 3-77
General ; ,···· ·· 3-77
Adjustment/Testing 3-77
Flywheel End Play 3-77
Flywheel End Play Shims (table) 3-77
Gearshaft Bearings (table) 3-77
Disassembly
7
3-78
Crankcase Halves 3-78
Flywheel/Connecting Rod Assembly 3-81
Cleaning/Inspection 3-81
Flywheel/Connecting Rod Assembly 3-81
Fitting Sprocket Bearings 3-81
Fitting Pinion Bearings 3-81
Race Diameter and Crank Pin Size (table) 3-82
Pinion Shaft Bearing Selection (table) 3-85
Lapping Engine Main Bearing Races 3-85
Assembly 3-85
Crankcase Halves 3-85
ix
Page No Page No
SECTION 4-FUEL SYSTEM 4 8 Initial Diagnostic Check 4-13
4 1 Dynamic Digital
Fuel Injection 4-1
Introduction 4-1
General 4-1
For More Information 4-1
Troubleshooting 4-1
Fuel Injection Components 4-1
4 2 Diagnostic Introduction 4-3
System Problems 4-3
No Start 4-3
Poor Performance 4-3
Check Engine Lamp 4-3
Resolving Problems 4-3
4 3 Checking For Trouble Codes 4-4
Model Year Change 4-4
Check Engine Lamp : 4-4
Code Types 4-5
Current 4-5
Historic 4-5
Functional 4-5
Retrieving Trouble Codes 4-5
Multiple Trouble Codes 4-5
4 4 Scanalyzer 4-6
Scanalyzer Diagnostics 4-6
Data Link Connector 4-6
Scanalyzer Cartridge 4-6
Installation 4-6
Usage 4-8
Checking Codes 4-8
Clearing Codes 4-8
Removal 4-8
4 5 Check Engine Lamp
Diagnostics 4-9
Activation 4-9
Clearing Codes 4-1 0
4 6 Breakout Box 4-11
General 4-11
Installation 4-11
Removal 4-11
4 7 Wiggle Test 4-12
,>3eneral 4-12
Procedure 4-12
Using Scanalyzer 4-12
Using DVOM 4-12
x
General 4-13
Diagnostic Notes 4-13
Scanalyzer Icon : 4-13
Circuit Diagram/Wire Harness Connector Table 4-13
Jobf f ime Code Values 4-13
Initial Diagnostics 4-13
General Information 4-13
Diagnostic Tips 4-13
Diagnostic Notes 4-13
Typical Scan Values (table) 4-14
Engine Starts Hard (table) 4-14
Engine Performance Problems (table) 4-14
Engine Exhaust Emits Black Smoke (table) 4-14
Trouble Codes and Fault Conditions (table) 4-15
Wire Harness Connectors (table) 4-16
Diagnostic Check (Part 1 of 2) (flow chart) 4-17
Diagnostic Check (Part 2 of 2) (flow chart) 4-18
4 9 Check Engine Lamp Not
Illuminated at Key ON 4-19
General 4-19
Diagnostics 4-19
Diagnostic Tips 4-19
Diagnostic Notes 4-19
Wire Harness Connectors (table) 4-20
Test (flow chart) 4-21
4 10 Check Engine Lamp On
Continuously 4-22
General • 4-22
Diagnostics 4-22
Diagnostic Notes 4-22
Wire Harness Connectors (table) 4-23
Test (flow chart) 4-24
4 11 Engine Cranks But Will
Not Start 4 25
General 4-25
Diagnostics 4-25
Dia~ic Notes 4-25
Wire Harness Connectors (table) 4-25
Test (Part 1 of 3) (flow chart) ' 4-27
Test (Part 2 of 3) (flow chart) 4-28
Test (Part 3 of 3) (flow chart) 4-29
4 12 No ECM Power 4-30
General 4-30
Diagnostics 4-30
Diagnostic Notes 4-30
Wire Harness Connectors (table) 4-31
No ECM Power {flow chart) 4-32
Page No Page No
4 13 Fuel Pressure Test 4-33 4 19 Trouble Code 15 4-56
Inspection 4-33 General 4-56
Diagnostics 4-34 Intake Air Temperature Sensor 4-56
Diagnostic Notes 4-34
Wire Harness Connectors (table) 4-35
Test (Part 1 of 2) (flow chart) 4-36
Test (Part 2 of 2) {flow chart) 4-37
Diagnostics : 4-56
Diagnostic Tips 4-56
Diagnostic Notes 4-56
Scanalyzer Notes 4-56
4 14 Idle Speed Control 4-38
Intake Air Temperature Sensor
Specifications (table) 4-56
Adjustments 4-38 Wire Harness Connectors (table) 4-57
Code 15 Test (Part 1 of 2) (flow chart) 4-58
4 15 Misfire 4-39 Code 15 Test (Part 2 of 2) (flow chart) 4-59
General 4-39
Misfire At Idle or Under Load 4-39 4 20 Trouble Code 16 4-60
Diagnostics 4-39 General 4-60
Diagnostic Notes 4-39
Spark Plug Cables (table) 4-39
Wire Harness Connectors (table) 4-40
Test (Part 1 of 2) (flow chart) 4-41
Test (Part 2 of 2) (flow chart) 4-42
Battery Voltage 4-60
Diagnostics 4-60
Diagnostic Notes 4-60
Scanalyzer Notes 4-60
Wire Harness Connectors (table) 4-61
4 16 Trouble Code 11 4-43
Code 16 Test (Part 1 of 2) (flow chart) 4-62
Code 16 Test ( Part 2 of 2) (flow chart) 4-63
General 4-43
Throttle Position Sensor 4-43
Diagnostics 4-43
4 21 Trouble Codes 23 and 32 4-64
Diagnostic Tips 4-43 General 4-64
Scanalyzer Notes 4-43 Front Fuel Injector (Code 23) And Rear Fuel Injector
Diagnostic Notes 4-48 (Code 32) 4-64
Wire Harness Connectors (table) 4-44 Diagnostics 4-64
Code 11 Test (Part 1 of 2) (flow chart) 4-45
Code 11 Test (Part 2 of 2) (flow chart) 4-46
Diagnostic Notes 4-64
Scanalyzer Notes 4-64
4 17 Trouble Code 13 4-47
Wire Harness Connectors (table) 4-65
Code 23/32 Test (Part 1 of 2) (flow-chart) 4-66
General 4-47 Code 23/32 Test (Part 2 of 2) (flow chart) 4-67
Oxygen Sensor (02) 4-47
Diagnostics 4-47 4 22 Trouble Codes 24 and 25 4-68
Diagnostic Tips 4-47
Diagnostic Notes 4-47
Wire Harness Connectors (table) 4-48
Code 13 Test (Part 1 of 3) (flow chart) 4-49
Code 13 Test (Part 2 of 2) (flow chart) 4-50
General 4-68
Front Ignition Coil (Code 24)And Rear Ignition Coil
(Code 25) 4-68
Diagnostics 4-68
Code 13 Test (Part 3 of 3) (flow chart) 4-51 Diagnostic Notes 4-68
Scanalyzer Notes 4-68
4 18 Trouble Code 14 4 52 Wire Harness Connectors (table) 4-69
General 4-52
Code 24/25 Test (flow chart) 4-70
Engine Temperature Sensor 4-52
Diagnostics 4-52 4 23 Trouble Code 33 4 71
Diagnostic Tips 4-52
Diagnostic Notes 4-52
Scanalyzer Notes 4-52
Engine Temperature Sensor
Specifications (table) 4-52
Wire Harness Connectors (table) 4-53
General 4-71
Fuel Pump 4-71
Diagnostics 4-71
Diagnostic Notes 4-71
Scanalyzer Notes 4-71
Code 14 Test (Part 1 of 2) (flow chart) 4-54 Wire Harness Connectors (table) 4-72
Code 14 Test (Part 2 of 2) (flow chart) 4-55 Code 33 Test (flow chart) 4-73
xl
Page No Page No
4 24 Trouble Code 35 4-74 4 31 Sensors 4-94
General 4-74 General 4-94
Tachometer 4-7 4
Diagnostics 4-74
Diagnostic Notes 4-74
Wire Harness Connectors (table) 4-75
Oxygen Sensor 4-94
Removal 4-94
Installation 4-94
Engine Temperature Sensor 4-94
Model Year Change 4-94
Code 35 Test (flow chart) 4-76 Removal 4-94
Installation 4-94
4 25 Trouble Code 44 4-77
General 4-77
4 32 Bank Angle Sensor 4-95
Bank Angle Sensor 4-77
Diagnostics 4-77
Removal 4-95
Installation 4-95
Diagnostic Notes 4-77
Wire Harness Connectors (table) 4-78 4 33 Throttle Position Sensor 4-96
Code 44 Test (Part 1 of 2) (flow chart) 4-79 Removal 4-96
Code 44 Test (Part 2 of 2) (flow chart) 4-80 Installation 4-96
Calibration 4-96
4 26 Trouble Codes 52, 53, 54
and 55 4-81
4 34 Fuel Tank 4-97
Removal 4-97
General 4-81 Disassembly/Assembly 4-98
ECM Failure 4-81 Cleaning, Inspection and Repair 4-98
Installation 4-99
4 27 Trouble Code 56 4-82 Fuel Tank Pressure Test 4-99
General 4-82 4 35 Fuel Tank Vent Valve 4-100
Cam Sync Failure 4-82
Diagnostics 4-82
Diagnostic Notes 4-82
Wire Harness Connectors (table) 4-83
Model Year Change 4-100
General 4-100
Removal 4-100
Installation 4-100
Code 56 (Part 1 of 2) (flow chart) 4-84
Code 56 (Part 2 of 2) (flow chart) 4-85
4 28 Electronic Control Module 4-86
4 36 In line Fuel Filter 4-102
Model Year Change 4-102
Removal 4-86 General 4-102
Installation 4-86 Removal/Installation 4-102
4 29 Cam Position Sensor 4 37 Fuel Pump 4-103
and Rotor 4-88 Removal 4-103
Repair 4-103
Removal 4-88 Fuel Pump Replacement 4-103
Installation 4-91 Fuel Pressure Regulator Replacement 4-104
Low Fuel Level Sensor Replacement , 4-104
4 30 Ignition Coil 4-92
Installation 4-104
Troubleshooting 4-92
Ignition Coil Primary Circuit Test 4-92
Ignition Coil Secondary Circuit Test 4-92
Test Results 4-92
Ignition Coil Substitution 4-92
t' Removal , 4-93
4 38 Throttle Body and Manifold 4-105
General 4-1 05
Removal 4-105
Repair 4-106
Throttle Position Sensor 4-106
Fuel Injectors 4-106
Installation 4-93 Installation 4-107
xii
Page No
4 39 Air Cleaner 4-109
Removal 4-109
Inspection 4-109
Installation 4-109
4 40 Evaporative Emissions
Control-California Models 4-111
General 4-111
Troubleshooting 4-111
Removal 4-112
Vent Valve 4-112
Canister 4-112
Installation 4-112
Vent Valve 4-112
Canister 4-113
Hose Routing 4-113
Throttle Body Manifold 4-113
Canister Hose Routings 4-113
SECTION 5-ELECTRIC STARTER
5 1 Specifications 5-1
Starter 5-1
Service Wear Limits 5-1
Torque Values 5-1
5 2 Electric Starter System 5-2
General 5-2
Wiring Diagrams 5-2
Starter Relay 5-2
Starter Interlock 5-2
Operation 5-2
Troubleshooting (table) 5-4
5 3 Starting System Diagnosis 5-6
5 4 Starter Activation Circuits 5-8
5 5 Diagnostics/
Troubleshooting 5-9
General 5-9
Voltage Drops 5-9
5 6 Starter System Testing 5-11
"On Motorcycle" Tests 5-11
Starter Relay Test 5-11
Starter Current Draw Test 5-11
Page No
5 7 Starter 5-12
Removal 5-12
Testing Assembled Starter 5-12
Free Running Current Draw Test 5-12
Starter Solenoid 5-13
Solenoid Pull-in Test 5-13
Solenoid Hold-in Test 5-13
Solenoid Return Test 5-13
Disassembly, Inspection and Repair 5-14
Assembly 5-17
Installation 5-18
5 8 Starter Solenoid 5-19
General 5-19
Disassembly 5-19
Assembly 5-19
SECTION 6-DRIVE/TRANSMISSION
6 1 Specifications 6-1
Transmission 6-1
Transmission Gear Ratios 6-1
Primary Drive 6-1
Final Drive 6-1
Clutch Plate Thickness 6-1
Torque Values 6-2
6 2 Primary Chain ~················ 6-3
General 6-3
Adjustment/Lubrication 6-3
Removal 6-3
Primary Cover 6-3
Primary Chain Adjuster 6-4
Installation 6-4
Primary Chain Adjuster 6-4
Primary Cover 6-5
6 3 Secondary Drive Belt 6-6
General • 6-6
Removal 6-6
Installation 6-7
6 4 Clutch Release Mechanism 6-8
Adjustment : ·············· 6-8
Disassembly
Cleaning, Inspection and Repair
Assembly
6-8
6-8
6-9
xiii
Page No
6 5 Primary Drive/Clutch 6-10
General 6-1 0
Clutch Troubleshooting (table) 6-10
Removal/Disassembly 6-11
Clutch Pack ··················· 6-1 1
Primary Cham/Drive 6-13
Inspection/Repair 6-14
Assembly 6-15
Clutch Pack 6-15
Primary Drive 6-15
Installation 6-16
6 6 Transmission 6-11
Model Year Change 6-17
General 6-17
Lubrication 6-17
6 7 Transmission Case 6-19
General 6-19
Removal 6-19
Cleaning, Inspection and Repair 6-20
Neutral Indicator Switch : 6-20
6 8 Shifter Forks and Drum 6-21
Disassembly 6-21
Cleaning, Inspection and Repair 6-21
Assembly 6-22
6 9 Mainshaft and Countershaft 6-24
Disassembly 6-24
Cleaning, Inspection and Repair 6-27
Assembly 6-27
6 10 Main Drive Gear 6-30
Removal 6-30
Disassembly 6-31
Assembly 6-31
Installation 6-31
6 11 Access Door Bearings 6-32
Removal 6-32
Mainshaft and Countershafl Bearings 6-32
Shift Drum Bushing 6-32
Installation 6-32
Mainshaft and Counters haft Bearings 6-32
Shift Drum Bushing 6-32
6 12 Right Transmission
Case Bearings 6-33
Removal 6-33
Installation 6-33
f" Mainshaft 5th Gear Ball Bearing 6-33
Countershafl Needle Bearing 6-33
Shift Drum Needle Bearing 6-33
xiv
Page No
6 13 Transmission Installation and
Shifter Pawl Adjustment 6-34
SECTION 7-ELECTRICAL
7 1 Specifications 1-1
Battery 7-1
Spark Plugs 7-1
Alternator 7-1
Regulator 7-1
Ignition Coil Resistance 7-1
Electrical System 7-1
Bulb Chart 7-1
Torque Specifications 7-2
7 2 Ignition System 7-3
General 7-3
Troubleshooting 7-3
7 3 Ignition/Headlamp
Key Switch 7-5
General 7-5
Removal 7-5
Ignition Key Switch Positions (table) 7-5
Indicator Markers (table) 7-5
Installation 7-6
7 4 Spark Plug Cables 1-1
General 7-7
Removal - 7-7
Inspection 7-7
Installation 7-7
7 5 Starter Interlock 7-8
Model Year Change 7-8
General 7-8
Starter Circuit 7-8
Ignition Circuit 7-8
Starter Interlock Troubleshooting (table) 7-8
Diagnostics 7-9
Ignition Test (flow chart) 7-10
Starter Test (Part 1 of 2) (flow chart) 7-1 0
Starter Test (Part 2 of 2) (flow chart) 7-11
Testing/Replacement 7-13
Side Stand Switch 7-13
Clutch Switch 7-13
Ignition Relay 7-14
Starter Relay 7-14
Ignition Fuse 7-14
Diodes 7-14
Main Circuit Breaker 7-14
\
7 6 Charging System 7-15
General 7-15
Alternator 7-15
Voltage Regulator 7-15
Troubleshooting 7-15
Battery 7-15
Wiring 7-15
Voltage Regulator Inspection 7-15
Testing 7-18
Voltage Regulator Bleed Test 7-18
Milliampere Draw Test 7-18
Total Current Draw Test 7-18
Current and Voltage Output Test 7-19
Voltage Output Test 7-19
Stator Check 7 -19
AC Output Check 7-20
7 7 Alternator 7-21
Removal/Disassembly 7-21
Rotor 7-21
Stator 7-21
Cleaning, Inspection and Repair 7-22
Assembly/Installation 7-22
7 8 Voltage Regulator 1-23
General 7-23
Removal 7-23
Installation 7-23
7 9 Battery (1999 Models) 1-24
General 7-24'
Testing 7-24
Open Circuit Voltage Test 7-24
Charging Rates (table) 7-24
Load Test 7-25
Charging Battery 7-25
7 1 0 Battery Cables
(1999 Models) 7-26
Removal 7-26
Installation 7-26
Installation 7-26
7 11 Battery (2000 Models) 1-28
General 7-28
Battery Testing 7-28
Voltmeter Test 7-28
Disconnection and Removal 7-29
Cleaning and Inspection 7-29
Battery Charging 7-29
Safety Precautions 7-29
Charging Battery 7-29
Battery Charging Rates and Times (table) 7-30
Battery Testing 7-30
Load Test 7-30
,-, Battery Cable Routing 7-31
Battery Installation and Connection 7-31
Battery Stocking and Selling 7-33
\
7 12 Headlamp 1 34
Removal/Disassembly 7-34
Removal 7-34
Headlamp Bulb 7 34
Headlamp Housing and Brackets 7-34
Installation 7-35
Headlamp Bulb 7-35
Headlamp Housing and Brackets 7-35
7 13 Tail Lamp 7-36
Removal/Disassembly 7-36
Assembly/Installation 7-36
7 14 Turn Signals 7-37
Removal 7-37
Bulbs 7-37
Front 7-37
Rear 7-37
Installation 7-37
Front 7-37
Rear 7-38
7 15 Turn Signal Flasher 7 39
Removal 7-39
Installation 7-39
7 16 Handlebar Switches 7-40
Removal 7-40
Right Side 7-40
Left Side 7-40
Installation 7-41
Right Side 7-41
Left Side 7-41
7 17 Speedometer Senso~ 7 43
Removal 7-43
Installation 7-43
7 18 Speedometer 1-«
General 7 -44
Removal 7-44
Installation 7-45
7 19 Tachometer 7-46
General 7-46
Removal 7-46
Installation 7·47
7 20 Speedometer
Performance Check 7-48
General 7-48
Testing 7-48
Speedometer Operation Test 7-48
Speedometer Test Frequency (table) 7·48
Speedometer Needle Sweep Test 7-49
Speedometer Sensor Test 7-49
Speedometer Test: Chart 1 (flowchart) 7-50
Speedometer Test: Chart 2A (flowchart) 7-51
Speedometer Test: Chart 2B (flow chart) 7-52
xv
7 21 Tachometer Performance
Check 7-53
General 7-53
Testing 7-53
Operation Test 7-53
Tachometer Accuracy Tolerances (table) 7-53
Sweep Test 7 -53
7 22 Horn 7-54
Removal 7-54
Installation 7-54
Troubleshooting 7-55
7 23 Neutral Indicator Switch 7-56
General 7-56
Testing 7-56
Removal/Installation 7-56
7 24 Fuses and Circuit
Breakers 1-51
General 7-57
Fuses 7-57
Master Circuit Breaker 7-57
7 25 Electrical Connectors 7-58
General 7-58
Electrical Connectors (Table) 7-58
7 26 Deutsch Electrical
Connectors 1-ss
General 7-59
Removing/Installing Sockets 7-59
Removing/Installing Pins 7-59
Assembly/Installation 7-59
Crimping Instructions 7-60
7 27 Amp Multilock Electrical
Connectors 1-61
Removing Socket/Pin Terminals 7-61
Installing Socket/Pin Terminals 7-62
Crimping Instructions 7-63
Wiring Diagram 7-65
APPENDIX
l"Appendix A-Tools A-1
Appendix 8-Metric Conversions
Index a-z 530

S.M 21/3/2025